End cap

ABSTRACT

An improved end cap for encircling the end of a package containing an article such as a bathtub or other articles. The improved end cap is formed as a generally four-sided paper member which has a plurality of first flaps formed around the sides of the paperboard member as well as a plurality of second flaps formed on the first flaps. The first and second flaps are foldable to a position which is generally perpendicular to the position of the four-sided member and are interlocked with each other to add torsional stability to the ends of the package with the first and second flaps also serving as cushions to cushion the article contained in the package.

1451 Nov. 11, 1975 muted States Patent Poggiali U.S. Patent N0v.11,1975 sheemofz 3,918,580

sheet 2 of 2 31,918,580

U.S., Pant. Nov. 11, 1975 END CAP CROSS REFERENCES TO RELATED APPLICATIONS `A. Coons et al and entitled End Cap for Package".

BACKGROUND OF THE INVENTION This invention relates generally to a paperboard package and more particularly relates to a new and improved end cap for a shipping package which has improved torsional stability as well as providing improved cushioning for the article contained in the package. In the handling of residential bathtubs formed of pressed steel, special problems were encountered in preparing the bathtubs for shipping and storage due to the large heavy size of the bathtub as well as their finished surfaces which had to be free from damage when installed in the ultimate users home. Prior art bathtub containers are known which are formed by manufacturing a wooden crate and placing the bathtub therein for shipment to the consumer. One such bulky bathtub container is shown in the U.S,. Pat. No. 3,099,351 issued on July 30, 1963 to Coffey. Bathtub containers such as this while protecting the bathtub during the trip to the consumer, often increase the handling problems of the tub due to the extra weight encountered with the use of the heavy wooden frame used to surround the tub.

Thereafter efforts were made to reduce the weight of the heavy wooden crate by the use of a combination of wood and paperboard without destroying the effectiveness of the protection afforded by the container. One such effort is shown in U.S. Pat. No. 3,194,395, issued July 13, 1965 to Weaver et al wherein a combination of wooden end caps are used in conjunction with paperboard top and bottom panels which are banded to the wooden end cap at the end of the package. Such a package, while serving its ultimate purpose, still required a fabrication of heavy wooden end caps which added greatly to the cost of the entire package. Further attempts at reducing the cost of the package resulted in the configuration shown in U.S. Pat. No. 3,487,914, issued Jan. 6, 1970 to Weaver et al which attempted to eliminate the wooden end caps by the use of paperboard end caps but which still required wooden reinforcements in the end caps in order to obtain necessary structural stability and cushioning necessary for the bathtub package. Other attempts have been made to utilize an all paperboard shipping package as shown by the U.S. Pat. No. 3,289,825, issued Dec. 6, 1966 to Smith and the U.S. Pat. No. 3,486,612 issued Dec. 30, 1969 to Kivell. Both of these structures, while eliminating the wooden slats of reinforcements heretofore mentioned, obtained a cushioning at the expense of having to use many cardboard padded pieces placed at the various critical positions within the bathtub for cushioning that portion of the bathtub during a shipment. Such multi-piece packages were not easily assembled and were expensive to construct.

A somewhat different approach was attempted in the U.S. Pat. No. 3,521,744, issued July 28, 1970 to Smith wherein the patentee attempted to achieve the necessary structural stability by using an elongated wooded rod at the lower rear feet ofthe tub in combination with a partial wooden end frame and a paperboard overlaying tube in combination with previously tried cardboard cushions. This design, like other attempted designs using wood framing, was still expensive to manufacture and did not provide the ultimate in a desired shipping container from the consumers standpoint.

In the beforementioned paragraph entitled Cross References to Related Applications, reference was made to the U.SA Ser. No. 223,582 filed Feb. 4, 1972 by Everett A, Coons et al. In the invention disclosed in that application, there is shown a new and novel approach to a bathtub container package and one which utilizes a new and novel end cap which is disclosed in the co-pending divisional application Ser. No. 325,048, filed Jan. l0, 1973 by Everett A. Coons et al. While this last mentioned end cap design was satisfactory for the purposes intended, during the natural evolution of a package, the subject end cap was designed which has new and improved features over the beforementioned end cap.

SUMMARY OF THE INVENTION In order to overcome the problems inherent in the beforementioned prior art shipping packages, there is provided by the subject invention a new and novel end cap for a shipping package which comprises a generally four-sided paperboard member which has a plurality of first flaps formed on at least a portion of the sides of the four-sided member and are hingedly attached thereto. In addition a plurality of second flaps are formed on and hingedly attached to at least a portion of said first flaps and are foldable in juxtaposition to said first flaps to a position that is generally perpendicular to the position of the four-sided member. Formed on a portion of the flaps are means for interlocking the respective flaps together to add torsional stability to the ends of the package with the folded up first and second flaps serving as a cushion to cushion the article in the package.

Accordingly is an object ofthe invention to provide a new and novel end cap for an article carrying package which may be constructed in a generally one-piece configuration and which has a plurality of flaps hingedly attached thereto which roll up to provide a cushioning effect on the article contained within the package.

Yet another objectof the invention is to provide a new and improved end cap for an article containing package which has a plurality of cushioning members formed integrally with the end cap with the cushioning members being interlocked in such a manner as to impart torsional stability and rigidity to the end cap.

Still yet another object of the invention is to provide a new and novel improved end cap for a wrap-around bathtub package which has a plurality of built-in cushioning members which form a four-sided cushioning for the bathtub contained within the package with the cushioning members being interlocked to each other.

Yet another object of the invention is to provide a new and novel end cap for a package which is formed in a one-piece construction and which may be quickly and easily assembled at the assembly point and locked in position for insertion into the ends of the package which it fits.

These and other objects and advantages of the invention will become apparent after a study of the drawings and after reviewing the specification describing the preferred embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. l is a perspective view of the bathtub package utilizing the new and novel end caps of the invention and showing the end caps in position at each end of the package within the wrap-around tube member of the package;

FIG. 2 is a plan view of the production blank for one of the end caps of the invention;

FIG. 3 is a perspective view showing one of the end caps of the invention prior to its being folded up to its ultimate position;

FIG. 4 is a perspective view of the end caps shown in FIG. 3 showing it further partially folded up;

FIG. 5 is a perspective view of the end cap shown in FIG. 4 showing it still further partially folded up;

FIG. 6 is a perspective view of the end cap shown in FIG. 5 completely folded up ready for insertion into the bathtub package; and

FIG. 7 is a sectional view, taken along line 7 7 of FIG. 6 showing a bathtub positioned in and protected by the end cap.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings in general and particularly to FIG. l of the drawing there is shown the new bathtub package l0 of the type utilizing the new and improved end caps l2 and 14 which may be formed from corrugated paperboard and generally comprise a four-sided paperboard member 16 having a plurality of handholes 18 formed in the central portion thereof. The end caps l2 and 14 are utilized to close the end of the' bathtub package tube member 20 in the manner more fully described in the beforereferenced paragraph entitled Cross References to Related Applications.

The four-sided paperboard member 16 which forms the end caps for the bathtub package has formed on one side thereof, by means of the scoreline 22 a first flap 23 in the form of a top flap which is ultimately utilized to cushion the top of the bathtub packaged within the bathtub package. The top flap has formed thereon by means of a plurality of die cuts 24, 26 and 28 in combination with a plurality of slit hinges 30 and 32, a second flap 34 in the general configuration shown.

The second flap 34 has hingedly attached thereto a plurality of cushioning flaps 36, 38 and 40 as is more fully detailed in the beforementioned U.S. Pat. application Ser. No. 325,048. The first flap top flap 23 also has formed on the ends thereof by means of the scorelines 42 and 44 a plurality of interlocking flaps 46 and 48 whose function will be described more fully hereinafter. By interlocking it is meant that any part or flap is connected to an adjacent part or flap so that motion of any parts is constrained in one or several directions.

The interlocking 46 has a recessed portion 50 formed i on one edge thereof while the interlocking flap 48 has a recessed portion S2, of somewhat different configuration, formed on one edge of that flap.

The four-sided paperboard member 16 also has formed on another side another first flap 54 by means of the scoreline 56. Formed on the side of the first flap S4 is a second flap 58, formed by means of a plurality of die cuts 60, 62 and 64 in combination with a plurality of slit hinges 66 and 68.

The first flap 54 is generally referred to as the rear flap since it serves to cushion the rear portion of the bathtub contained in the package as will be more fully described hereinafter. Opposite the rear flap and formed on another side of the four-sided paperboard member 16 is another first flap 70 known generally as the front flap since it serves to cushion the front ofthe bathtub contained within the package. The front flap 70 is formed by means of the scoreline 72 and has formed on its side thereof a second flap 74, formed by means of the die cuts 76, 78 and 80 in combination with the slit hinges 82 and 84.

Formed on the remaining sides of the four-sided paperboard member 16 is another first flap 86 which is known generally as the bottom flap since it cushions the bottom of the bathtub contained within the package. The bottom flap 86 is formed by means of the scoreline 88 and has formed on its side thereof a second flap 90, formed by means of the plurality of die cuts 92, 94 and 96 in combination with the plurality of slit hinges 98 and 100. The bottom flap 86 has formed on one end thereof, by means of the scoreline 102 an interlocking flap 104 which serves as a means for interlocking the various flaps together as will be more fully described hereinafter. The second flap also has formed on one of its ends, by means of the scoreline 106, a interlocking flap 108. The interlocking flap 108 also has formed along one side thereof` a recessed portion 110 while the interlocking flap 104 has formed along one of its sides thereof a recessed portion 112 whose function will be more fully described hereinaftel.

Referring now to the drawings FIGS. 3-6 there will be shown the folding sequence in folding the new and novel end cap into its final position to form the cushioning members and the interlocking of the respective flaps with each other. Prior to folding of the end cap into its interlocked position, the three cushioning flaps 36, 38 and 40 have been rolled up into the position shown in FIG. 3 of the drawing and as more fully described in the beforementioned U.S. Pat. application Ser. No. 325,048. Thereafter the second flap 90 is folded downwardly into juxtaposition with its respective first flap or bottom flap 86 and there respective interlocking flaps 108 and 104 are folded inwardly as shown in FIG. 3 of the drawing.

By referring now to FIG. 4 of the drawing there is shown the next folding sequence where the bottom flap 86 along with the second flap 90 have been folded downwardly so that they are in a position substantially perpendicular to the four-sided member 16 and so their respective interlocking flaps 104 and 108 are also folded downwardly to be substantially perpendicular to the four-sided member 16. In a similar manner the interlocking flaps 46 and 48 are folded upwardly so that they are substantially perpendicular to the four-sided member 16 leaving them in the position shown in FIG. 4 of the drawing in line with the interlocking flaps 104 and 108.

Referring now to FIG. 5 of the drawing there is shown the next to final folding sequence wherein the front flap 70 and the rear flap 54 along with their second flaps '74 and 58 are folded around the interlocking flaps 46, 48, 104 and 108. When folded in this manner the recessed portion 50 of the interlocking flap 46 will engage the slit hinge 68 and the recessed portion 110 of the locking flap 108 will engage the slit hinge 66. In a similar manner the recessed portion S2 of the interlocking flap 48 will engage the slit hinge 84 while the recessed portion 112 of the interlocking flap 104 will engage the slit hinge 82 to interlock the respective flaps to each other to provide the torsional stability to the package. When folded in this manner the front edge 123 of the bathtub may be cushioned by the combination of the interlocking flaps ft and 4S being positioned between the first flap 70 and the second flap 74 while the rear edge 124 of the bathtub may be cushioned by the combination ofthe flaps 108 and 46 being folded between the first flap S4 and the second flap 58 as shown in FIG. 7 ofthe drawings. In alike manner the bottom edge 125 of the bathtub may be cushioned by the combination of the first flap 86 being folded in juxtaposition to the second flap 90.

By referring now to FIG. 6 of the drawing there is shown the final folding sequence in which the three cushioning flaps 36, 38, and 40 are then folded inwardly into the end cap package with the cushioning flap 36 being in juxtaposition to the top flap 23. By referring to FIG. 2 of the drawing it should be noted that the second flap 58 is somewhat shorter than the first flap 56 by the amount of the distance shown on the drawing as 114 and the second flap 74l is somewhat shorter than the first flap 70 by the distance shown on the drawing as 116. When formed in this manner the three cushioning flaps 36, 38 and 40 as well as the second flap 34 are locked into the package or wedged between the ends of the second flaps 58 and 74 at the position shown as 118 and 1120 on the drawing in FIG. 6. As a result the entire end package is now completely interlocked together and is ready for insertion into the bathtub package tube member 2t) in a manner similar to that described in the beforementioned pending patent application and as shown in FIG. 7 with the top edge 126 being cushioned by the second flap 34.

When formed in this manner it can be seen that the top edge 126 of the bathtub will rest on the second flap 34 and will be cushioned by the top flap 23 as well as the second flap 34 and the three cushioning flaps 36, 38, and 40. In a similar manner the bottom edge 125 of the bathtub will rest on the second flap 90 and will be cushioned by the second flap 9@ as well as the bottom flap 36. In a like manner the front edge 123 of the bathtub will rest on the second flap 741 and be cushioned by the second flap 74 as well as the front flap 70 and the two interlocking flaps 43 and llilltl that are positioned between the front flap 70 and the second flap 7f3. And similarly the rear edge 124 of the bathtub will rest on the second flap 53 and will be cushioned by the second flap 58 as well as by the rear flap 54 and the two interlocking flaps d6 and 103 positioned between the rear flap 54 and the second flap 58.

While the interlocking flaps have been formed on the top flap 23 and on the bottom flap 86 as well as on the second flap 90, it will become apparent that the interlocking flaps may also be formed on other flaps of the package such as the rear flap 54, the front flap 70, the second flap 56, the second flap 74, and others without departing from the spirit and scope of the invention. In a similar manner it should become apparent that the improved end cap can be formed as a generally foursided member having four-sided cushioning and interlocking or may be formed as a four-sided or other-sided member having less than four-sided cushioning and interlocking by the removal of several of the flaps beforementioned. However, when formed as the generally four-sided member shown in the drawings, and having four-sided cushioning, the total flaps are interlocked with each other giving a greater degree of stability to the package caused by torsional rotation of the ends of the package or caused by a force impact on the ends of 5 the package in a direction generally perpendicular to the longitudinal direction of the tube member 20.

From the foregoing, it can be seen that a new and novel end cap has been provided for a wrap-around article package of the type which accomplishes all of the objects and advantages of the invention. Nevertheless, it is apparent that many changes in details of construction or arrangements of the parts of the package may be made without departing from the spirit and scope of the invention as expressed in the accompanying claims and the invention is not to be limited to the exact manner shown and described since only the preferred embodiment has been given by way of illustration.

Having described the invention, I claim:

l. An improved three piece bathtub package comprising a. a wrap-around tube member for encircling the bathtub;

b. a pair of end caps positioned in each end of the tube member for enclosing the ends of the bathtub package;

1. at least one of said end caps comprising a foursided paperboard member having formed thereon adjacent cushioning flaps, at least one of said pairs of adjacent. flaps having formed thereon interlocking means for interlocking the adjacent cushioning flaps together thereby adding torsional stability to the bathtub package, and

2. said interlocking means including an elongated flap having a recessed portion for engagement with the adjacent cushioning flap.

2. The improved package as dened in claim 1 wherein said cushioning flaps comprise at least a first flap hingedly attached to the four-sided paperboard member, a hinge attached to the first flap, and at least a second flap attached to the first flap by the hinge and further comprising said interlocking means being located between said first and second flaps and in engagement with the hinge between the first and second flaps.

3. The improved package as defined in claim 2 wherein said second flap is shorter than said first first flap for wedging said second flap and an adjacent cushioning flap together.

50 4. An improved end cap for enclosing the end of a package containing an article comprising:

a. a four sided paperboard member; b. a plurality of first flaps formed on at least a portion of the sides of said four-sided member and hingedly flaps and being foldable so as to extend between an adjacent first and second flap, and

means on said interlocking flap disposed between said adjacent first and second flaps and cooperating with the hinge connecting said adjacent first and second flaps to preclude relative movement of said interlocking flap, said means interlocking the respective flaps together thereby adding torsional stability to the end of the package.

S. The improvement as defined in claim l wherein said first flaps are formed respectively as a top flap, a bottom flap, a rear flap and a front flap.

6. The improvement as defined in claim 5 wherein said second flaps are connected to on each of said top, bottom, rear and front flaps.

, 77. The improvement as defined in claim 6 wherein a plurality of interlocking flaps are formed on and hingedly attached to at least the top flap.

8. The improvement as defined in claim 6 wherein an interlocking flap is formed on and hingedly attached to at least both said bottom flap and the second flap connected to said bottom flap.

9. The improvement as defined in claim 6 wherein a plurality of interlocking flaps are formed on and hingedly attached to at least the bottom flap and the top flap.

l0. An end cap production blank of the type utilized to form a cushioned end cap, comprising:

a. a four-sided paperboard member b. a top flap, hingedly attached to one side of said member; l. at least one slit hinge attached to said top flap; 2. a cushioning flap attached to said top flap by said slit hinge; c. a bottom flap, hingedly attached to another side of said member;

l. at least one slit hinge attached to said bottom flap;

2. a cushioning flap attached to said bottom flap by said slit hinge;

d. a front flap, hingedly attached to a further side of said member` l. at least one slit hinge attached to said front flap;

2. a cushioning flap attached to said front flap by said slit hinge;

e. a rear flap, hingedly attached to the remaining side of said member,

l. at least one slit hinge attached to said rear flap;

2. a cushioning flap attached to said bottom flap by said slit hinge; and

f. an interlocking flap, formed on and hingedly attached to one of said flaps and having a recessed portion thereon to engage the slit hinge attached to an adjacent cushioning flap, for interlocking the respective flaps together whenever the production blank is formed into a cushioned end cap thereby adding torsional stability to the ends of the package.

l1. The production blank as defined in claim l0 further comprising the interlocking flap being formed on at least the top flap.

l2. The production blank as defined in claim 10 further comprising the interlocking flap being formed on at least the bottom flap.

13. The production blank as defined in claim 10 further comprising the interlocking flap being formed on at least the top flap and the bottom flap.

14. The production blank as defined in claim l0 further comprisng the interlocking flap being formed on the cushioning flap attached to the bottom flap.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PATENT No. 3 ,918 580 DATED November l1, 1975 INVENTOR(S) Lewis Du Poggiali It is certified that error appears inthe above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column l, line 65, change "wooded to -wooden.

Column 3, line 56, after "interlocking" insert flap.

Column 5, line 9, before "flaps 108" insert interlocking.

Signed and Sealed this fifteenth of June 1976 [sEALl Attest.'

RUTH C. MASON C. MARSHALL DANN tmm'ng Ufficer Cummisslifmer nfParenls and Trademarks 

1. An improved three piece bathtub package comprising a. a wrap-around tube member for encircling the bathtub; b. a pair of end caps positioned in each end of the tube member for enclosing the ends of the bathtub package;
 1. at least one of said end caps comprising a four-sided paperboard member having formed thereon adjacent cushioning flaps, at least one of said pairs of adjacent flaps having formed thereon interlocking means for interlocking the adjacent cushioning flaps together thereby adding torsional stability to the bathtub package, and
 2. said interlocking means including an elongated flap having a recessed portion for engagement with the adjacent cushioning flap.
 2. a cushioning flap attached to said bottom flap by said slit hinge; and f. an interlocking flap, formed on and hingedly attached to one of said flaps and having a recessed portion thereon to engage the slit hinge attached to an adjacent cushioning flap, for interlocking the respective flaps together whenever the production blank is formed into a cushioned end cap thereby adding torsional stability to the ends of the package.
 2. a cushioning flap attached to said front flap by said slit hinge; e. a rear flap, hingedly attached to the remaining side of said memBer,
 2. a cushioning flap attached to said bottom flap by said slit hinge; d. a front flap, hingedly attached to a further side of said member,
 2. a cushioning flap attached to said top flap by said slit hinge; c. a bottom flap, hingedly attached to another side of said member;
 2. The improved package as defined in claim 1 wherein said cushioning flaps comprise at least a first flap hingedly attached to the four-sided paperboard member, a hinge attached to the first flap, and at least a second flap attached to the first flap by the hinge and further comprising said interlocking means being located between said first and second flaps and in engagement with the hinge between the first and second flaps.
 2. said interlocking means including an elongated flap having a recessed portion for engagement with the adjacent cushioning flap.
 3. The improved package as defined in claim 2 wherein said second flap is shorter than said first first flap for wedging said second flap and an adjacent cushioning flap together.
 4. An improved end cap for enclosing the end of a package containing an article comprising: a. a four sided paperboard member; b. a plurality of first flaps formed on at least a portion of the sides of said four-sided member and hingedly attached thereto; c. a plurality of second flaps, each associated with a respective first flap; d. at least one hinge connecting each of said second flaps to its respective first flap so that each second flap is foldable into juxtaposition with said respective first flap; e. said first and second flaps being foldable to a position generally perpendicular to the position of said four-sided member and serving as a cushion to cushion the article contained in the package; f. at least one interlocking flap formed on and hingedly attached to one of said first and second flaps and being foldable so as to extend between an adjacent first and second flap, and means on said interlocking flap disposed between said adjacent first and second flaps and cooperating with the hinge connecting said adjacent first and second flaps to preclude relative movement of said interlocking flap, said means interlocking the respective flaps together thereby adding torsional stability to the end of the package.
 5. The improvement as defined in claim 1 wherein said first flaps are formed respectively as a top flap, a bottom flap, a rear flap and a front flap.
 6. The improvement as defined in claim 5 wherein said second flaps are connected to on each of said top, bottom, rear and front flaps.
 7. The improvement as defined in claim 6 wherein a plurality of interlocking flaps are formed on and hingedly attached to at least the top flap.
 8. The improvement as defined in claim 6 wherein an interlocking flap is formed on and hingedly attached to at least both said bottom flap and the second flap connected to said bottom flap.
 9. The improvement as defined in claim 6 wherein a plurality of interlocking flaps are formed on and hingedly attached to at least the bottom flap and the top flap.
 10. An end cap production blank of the type utilized to form a cushioned end cap, comprising: a. a four-sided paperboard member b. a top flap, hingedly attached to one side of said member;
 1. at least one slit hinge attached to said top flap;
 2. a cushioning flap attached to said top flap by said slit hinge; c. a bottom flap, hingedly attached to another side of said member;
 1. at least one slit hinge attached to said bottom flap;
 2. a cushioning flap attached to said bottom flap by said slit hinge; d. a front flap, hingedly attached to a further side of said member,
 1. at least one slit hinge attached to said front flap;
 2. a cushioning flap attached to said front flap by said slit hinge; e. a rear flap, hingedly attached to the remaining side of said memBer,
 1. at least one slit hinge attached to said rear flap;
 2. a cushioning flap attached to said bottom flap by said slit hinge; and f. an interlocking flap, formed on and hingedly attached to one of said flaps and having a recessed portion thereon to engage the slit hinge attached to an adjacent cushioning flap, for interlocking the respective flaps together whenever the production blank is formed into a cushioned end cap thereby adding torsional stability to the ends of the package.
 11. The production blank as defined in claim 10 further comprising the interlocking flap being formed on at least the top flap.
 12. The production blank as defined in claim 10 further comprising the interlocking flap being formed on at least the bottom flap.
 13. The production blank as defined in claim 10 further comprising the interlocking flap being formed on at least the top flap and the bottom flap.
 14. The production blank as defined in claim 10 further comprising the interlocking flap being formed on the cushioning flap attached to the bottom flap. 